Method and apparatus for spooling wire



July 29, 1958 G. L. BLISS METHOD AND APPARATUS FOR SPOOLING WIRE Filed June 3, 1954 FIG. 1.

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U W L H w f 05. Z m 4 1%. W U f E 3 F Mg: Uv 3% 3i 1 MU w w, a W pv I IIII MMNM NV Oc w E I nited States Patent METHOD AND APPARATUS FOR SPOOLING WIRE George L; Bliss, Cleveland, Ohio, assignor to United States Steel Corporation, a corporation of New Jersey Application June 3, 1954, Serial No. 434,298

12 Claims. (Cl. 242-25) This invention relates to an improved method and apparatus for spooling wire.

Conventional wire spooling machines are equipped with traversing means for winding the wire evenly on the spool. The usual traversing means includes a carriage which travels back and forth along the length of the spool and guides the wire in its approach. Most traversing carriages travel at a present rate which at any given setting remains constant with respect to that of the spool. Because of variations in the wire diameter, they are incapable of winding perfect coils, that is, coils in which the wire has an accurate thread lay and whose reversals are located precisely at the ends of the wire receiving portion of the spool unaccompanied by any piling up. If there are gaps between successive convolutions, wire from an overlying layer can enter and impede subsequent unwinding. Any winding irregularities tend to be cumulative. Imperfect coils can cause operating difiiculties in various automatic machines, such as balers. If the wire snarls as it pays off, such machines cannot operate.

An object of the present invention is to provide an improved wire spooling method and apparatus which eliminate irregularities in winding and thus assure more nearly perfect coils.

A further object is to provide an improved wire spooling method and apparatus which automatically correct the winding at the end ofeach layer on the spool and thus overcome the tendency for irregularities to be cumulative.

A more specific object is to provide an improved wire spooling method and apparatus in which the traversing carriage tends to lag behind the wire on the spool until the latter reaches 'a fixed point near the end of each layer to assure tight winding, and then accelerates to overtake the wire at the reversal point.

In accomplishing these and other objects of the invention, I have provided improved details of structure, preferred forms of which are shown in the accompanying drawings, in which:

Figure 1 is a schematic top plan view of a spooling apparatus constructed in accordance with my invention;

Figure 2 is a wiring diagram of the apparatus shown in Figure 1;

Figure 3 is a schematic top plan view of a modification;

Figure 4 is a wiring diagram of the apparatus shown in Figure 3; and

Figure 5 is a sectional view of the epicyclic gear train embodied in both forms of the apparatus.

Figure 1 shows somewhat diagrammatically a typical spooling apparatus which comprises a spool 10, a shaft 12 supporting the spool, and a motor 13 and speed reducer 14 for driving the shaft and spool. Wire W from a preceding piece of equipment winds on the spool and is guided thereon by a traversing means. The latter includes a screw 15 and a carriage 16 mounted thereon. The screw 15 is journaled in spaced parallel relation C ice with the spool shaft 12 and is driven therefrom via a chain and sprocket connection 17, a variable speed transmission 18, and a reversing mechanism 19. The reversing mechanism includes a drive pinion 20 connected with the transmission 18, a cooperating gear 21 on the screw 15 for rotating the latter to move the carriage 16 to the left, another cooperating gear 22 on the screw for rotating it the other way, and a spline clutch 23 for selectively. establishing a driving connection between the drive pinion and either of said gears.

A shift mechanism automatically operates the clutch 23 whenever the carriage 16 and wire, W reach one of the reversal points. The shift mechanism includes a control rod 24 supported in spaced parallel relation with the traversing screw 15 and a sleeve 25 which is fixed to the carriage 16 and rides on said rod. Left and right normally open limit switches 26 and 26a are fixed to opposite end portions of the rod. A solenoid operated shifter arm 28 is connected with the clutch 23. When ever the sleeve 25 abuts the left limit switch 26, it completes a circuit, hereinafter described, to shift the clutch 23 from a position in which the pinion 20 drives the gear 21 to a position in which it drives the gear 22. Consequently the direction of rotation of the screw is reversed. Whenever the sleeve abuts the right limit switch 26a, the opposite reversal takes place. The parts thus far mentioned and their operation are conventional and therefore they are not shown nor described in greater detail. They represent one form of machine to which my invention is applicable, although obviously it can be applied to other spooling machines and other forms of traversing means.

In accordance with my invention, an epicyclic gear train 31 is interposed between the spool shaft 12 and the traversing screw 15. As shown in Figure 5, this vgear train includes a sun gear 32 driven from the chain and sprocket means 17, a normally stationary ring gear 33, planetary gears 34, and a yoke 35, which is connected to the transmission 18 and on which said planetary gears are journaled. The ring gear 33 has external gear teeth as well as internal. An electric motor 36 is connected to a pinion 37 which meshes with the external gear teeth on the ring gear. Normally the motor 36 does not operate and is held against rotating to hold the ring gear stationary. Consequently the traversing screw is driven in the usual way at a preset constant rate relative to that of the spooling shaft 12. However, the motor can be operated to drive the ring gear 33 in the appropriate direction to turn the screw 15 faster than its relatively constant rate and thus accelerate the carriage 16.

In practice the actual diameter of the wire W varies within prescribed limits from its nominal diameter. The transmission 18 is set so that the carriage 16 would stay even with a wire of the minimum diameter within the prescribed range, as long as the motor 36 does not operate. Since the greater part of the wire is of somewhat larger diameter, the carriage tends to lag behind the wire. However, this is desirable until the wire reaches its reversal point in order to assure that the wire is wound tightly and that each convolution bears against the one preceding. To afford an accurate reversalit is necessary for the carriage and the wire to reach their reversal points simultaneously. My invention provides means for automatically operating the motor 36 at the approach of each reversal so that the carriage 16 overtakes the wire just ahead of the reversal points.

In the form of my invention shown in Figure 1, a guide arm 41 is pivoted to the top of the carriage 16' and carries eyelets 41 through which the wire passes on its way to the spool 10. The rear portion of the carriage carries spaced apart normally open electric switches 42 and 42a on opposite sides ofthe guide arm. As long as the carriage is even with thewire,.thearm 40 remains,in.a .midposition out of engagement with either of these switches. If the carriage is moving to the left, as illustrated, and is lagging/behind theiwire; theearm swings icounterclocle' wise from its.mideposition;andaengages'and.closes:;the switch 42.. Similarly;if:ithe;.carriage is movingto'the right, the.arm tmay ClOSGithfl switch 4241.: Whenever the arm closes oneof theseswitches, it conditions'a circuit to the motor 36; to drivezthe;traversingxscrew faster. Additional-normallyopenelectric'switches 43 and 43a are situateda short distancezaheadzofthe left and right reversal pointsrespectively. The sleeve .25:-of.the carriage has an actuator. 44 for-:these last named switches; Ifthe motor circuit is .conditioned whenzthe. actuator engages and closes either. switch 43,-. or:43a, the motor 36 commences togoperatet. As. .soon.as the'carriage overtakes the wire, the.arm;returns.:to:its mid-position and opens the motor. circuit. If the carriage is so far behind that it doesnot fully overtake therwire before they reach the reversal point, engagement of the sleeve with the limit switch 26 or 26a automatically opens the motor circuit, as hereinafter explained- Of course this condition indicates the need for adjustment in the machine.

Figure 2 shows a wiring diagram of a preferred operating circuit for the embodiment of Figure 1. This circuit includes lines 48. and: 49 connected to an outside power source. Switch 42is connected across these lines in series with the coil of a relay 50, which has two sets ofnormally open contacts. Similarly switch 43 is connected across these lines in series'with the coil of a relay 51, which also has two sets. of normally opencontacts. The left limit switch 26 is connected across these lines in series with the coil of;a relay 52,..whichhas 'two sets-of normally closed contacts; The terminals ofthe motor 36 are connected across these lines in series-with the-respective contactsofithe three relays 50, Sland 52.

When the guide arm closes the switch 42, relay picks up andcloses its contacts. When the actuator 44 closes the switch 43, relay. 51 picks up and closes its contacts. As long as the contacts of both relays 50 and 51 and the normally closed contacts of the relay 52 are closed, motor 36 is energized and thus accelerates the carriage '16. When the sleeve 25 closes the limit switch 26, relay 52 picks up and its normally closed contacts open. If the guide arm 40 has not already returned to its mid-position and opened the switch 42 to stop the motor 36, opening of the contacts'of relay 52 stops this motor.

The coil of a relay 53 is connected'across the lines 48 and149 in series with the limit switch 26. This relay has two sets ofnormally open contacts. A solenoid 54 for operating theclutch shifter 28 of the reverse mechanism 19 is connectedxacross these lines in series with the respective contacts of the relay 53. When the sleeve 25 closes the limit switch 26, relay 53 also picks up and closes its contacts, whereupon the solenoid 54 is energized. This solenoid moves the shifter arm 28 to a position in which the clutch 23connects the gear '22 to drive the traversing screw 15. Consequently the:direction of carriage movement is reversed.

The circuit also'xhas a duplicate setof switches 26a, 42a and 43a, duplicate relays 50a, 51a, 52a and 53a, and a duplicate solenoid 54a for effecting acceleration and reversal of the carriage 16 at its-reversal point at the right. These parts are connected in the same manner as the corresponding parts already described and the description ,isnot repeated;

Figures 3 and 4 show a modification in which a light sensitive relay replaces the mechanically movable guide arm 40 and the switches 42 and 42a. Since the various drive means are similar to those already described, their snowingis not repeated in Figure 3. In this modification the upper face of the carriage 16 has an eyelet for guiding the wire W; The front part of the carriage carries a photoelectric relay 61. When the carriage is even with the wire, the latter is directly over the light 4.5 sensitive. element of saidrelay, and thus darkens it. When the carriage lags behind the wire, the latter passes to one side of the light sensitive element of the photoelectric relay and thus exposes it to light. The modification embodies the same switches 26, 26a, 43 and 43a as the form already described.

Figure 4 shows a wiringdiagram of this modification. The photoelectric relay 61 controls a set of contacts 62 which open when the wire W darkens the light sensitive element and close when this element is exposed to light. l /hon these contacts close, they complete current paths to the coils of both the relays 50 and 50a which are connected in parallel with each other and in series with these contacts. The remainder ofjthe circuit and its operation are the same as already described, and hence the description is not repeated.

From the foregoing description it is seen that the pres ent invention aifords a simple method and apparatus for assuring that accuracy in spooling wire. The invention affords a means for winding the wire tightly and yet assures that the carriage and wire reach their reversal points simultaneously.

While two embodiments of my invention have been shown and described, it will be apparent that other adaptations and modifications may be made without departing from the scope of the following claims.

I claim:

l. A wire spooling apparatus comprising a spool adapted to have wire wound therearound in layers, drive means for rotating said spool, a traversing carriage adapted to travel backand'forth along the length of said spool and guidethe wire in its approach, drive means for said carriage adapted to move it through a major portionof the-length of said spool at a preset constant rate with respect to that of said spool independently of the angular relation of the wire to the spool and to reverse the direction of travel of said carriage when it reaches positions opposite the ends of the layers of wire on said spool, and-means controlled by the angularrelation of the wire to the spool for accelerating said carriage only as it approaches its reversal points when the carriage lags behind the wire on the spool.

2. An apparatus as defined in claim 1 in which said accelerating-means includes electric contacts positioned for actuation whenthe carriage nears its reversal points and an'electric motor-adapted to be energized through said contacts and operatively connected to said carriage for driving it faster than its preset constant rate.

31 An apparatus as defined in claim 1 in which said accelerating means includes an electric motor operatively connected to said carriage for driving it faster than its preset constant rate; and an energizing circuit for said motor including contacts which close when the carriage lags behind the wire to condition the circuit and contacts which close when said carriage. nears itsreversal pointsto complete the circuit when conditioned.

4. An apparatus as defined in claim 1 in which said accelerating means includes an electric motor, an epicyclic gear train in the drive means to said carriage normally transmitting movement to the carriage at a constant rate with respect to that of the. spool, said motor being operatively-connected with said gear tram for increasing the rate of carriage movement over the constant rate, and an energizing circuit for said motor including contacts positioned for actuation when thecarriage nears its reversal points.

5. A wire spooling apparatus comprising a spool adapted to have wire wound therearound in layers, drive means for rotating said spool, a traversing screw journaled in spaced parallel relation to said spool, a traversing carriage mounted onsaid screw and adapted to travel back and forth along the length of the spool and guide the wire in its approach, a first drive means for said screw adapted to rotate itat a preset constant rate with respect to that ofsaid spool and thus to propel said carriage at a similar constant rate, a reverse mechanism for reversing the direction of carriage travel when it reaches positions opposite the ends of layers of wire on said spool, and an additional drive means for said screw for driving it faster and thereby accelerating said carriage when the latter approaches its reversal points and is lagging behind the wire.

6. An apparatus as defined in claim 5 in which said additional drive means includes an electric motor, an epicyclic gear train in the first drive means for said screw normally transmitting movement to the screw at a constant rate with respect to that of the spool, said motor being operatively connected with said gear train for increasing the rate of rotationof the screw over the constant rate, and an energizing circuit for said motor operated by said carriage when it nears its reversal points.

7. An apparatus as defined in claim 5 in which said additional drive means includes an electric motor, an epicyclic gear train in the first drive means for said screw normally transmitting movement to the screw at a constant rate with respect to that of the spool, said motor being operatively connected with said gear train 1 for increasing the rate of rotation of the screw over the constant rate, an energizing circuit for said motor, conditioning contacts in said circuit, means operated by the wire when the carriage is lagging behind it for closing said conditioning contacts, and contacts operated by said carriage when it nears its reversal points for completing the circuit if said conditioning contacts are closed.

, 8. An apparatus as defined in claim 7 in which the operating means for said conditioning contacts includes a guide arm for the wire pivoted to the top of said carriage adapted to turn when the carriage lags behind the wire, and a switch mechanically operated by said arm.

9. An apparatus as defined in claim 7 in which the operating means for said conditioning contacts includes a light sensitive relay on said carriage positioned Where the wire covers it when the wire and carriage are even, but exposes it to light when the carriage lags behind the wire.

10. A wire spooling apparatus comprising a spool adapted to have wire wound therearound in layers, drive means for rotating said spool, a' traversing screw journaled in spaced parallel relation to said spool, a traversing carriage mounted on said screw and adapted to travel back and forth along the length of the spool and guide the wire in its approach, drive means for said screw adapted to rotate it at a preset constant rate with respect to that of said spool and thus to propel said carriage at a similar constant rate, a mechanism for reversing the direction of screw rotation and carriage travel, an electric circuit including limit switches actuated by said carriage when it reaches positions opposite the ends of layers of wire on said spool for operating said reversing mechanism, an epicyclic gear train in the drive means to said screw, an electric motor operatively connected with said gear train for rotating said screw faster than its constant rate and thereby accelerating said carriage, an energizing circuit for said motor, conditioning contacts in said energizing circuit, means operated by the wire when the carriage is lagging behind it for closing said conditioning contacts, contacts operated by said carriage when it nears its reversal points for completing said energizing circuit if said conditioning contacts are closed, and normally closed contacts opened by actuation of said limit switches for breaking said energizing circuit.

11. A method of winding wire in layers on a spool comprising guiding the wire in its approach on a traversing means, driving saidtraversing means through the major portion of the length of the spool at a preset constant rate with respect to that of the spool in accordance with the minimum diameter of the wire independently of the angular relation of the wire to the spool, and accelerating said traversing means in accordance with the angular relation of the wire to the spool as the wire nears its reversal points on the spool.

12. A method of winding wire in layers on a spool comprising guiding the wire in its approach on a traversing means, driving said traversing means through the major portion of the length of the spool at a preset constant rate with respect to that of the spool, said rate being determined by the minimum wire diameter independently of the angular relation of the wire to the spool whereby the traversing means tends to lag behind the wire, and accelerating said traversing means in accordance with the angular relation of the wire to the spool as the wire nears its reversal points whereby the traversing means overtakes the wire at the reversal points.

References Cited in the file of this patent UNITED STATES PATENTS 1,143,335 Underhill June 15, 1915 1,469,470 Wright Oct. 2, 1923 2,230,653 Nelson Feb. 4, 1941 2,255,935 Lewellen et a1. Sept. 16, 1941 2,345,601 Hickes Apr. 4, 1944 2,626,765 Biddison Jan. 27, 1953 

